Compact projection systems and related components

ABSTRACT

Projection systems and components thereof are described that are well suited to miniaturization. These systems and components may use one or more of the following features: a folded optical path, as in a reflective cavity or a beamsplitter; an illumination beam that is converging at the place where it impinges upon the spatial light modulator; a beamsplitter that uses opposed prisms of substantially different sizes; a beamsplitter whose obliquely disposed partial reflector defines a first rectangular reference space, and where at least a portion of the light source or at least a portion of the projector lens is disposed within such first rectangular reference space; a system in which a ratio of areas of the first rectangular reference space and a second rectangular reference space is within a specified range, where the second rectangular reference space is just large enough to encompass the optical components of the projector; a system in which the projector lens is small compared to the spatial light modulator.

FIELD OF THE INVENTION

This invention relates generally to optical projection systems, withparticular application to such systems that are small in size, e.g.,small enough so that all of the optical components of the projectionsystem can fit within the palm of one's hand, or so that the projectionsystem can be incorporated into a device or apparatus that can be wornby a user, such as a helmet, eyewear, or other headgear. The inventionalso relates to components relating to such projection systems, such ascompact polarized illuminators, compact polarizing beamsplitters, andrelated articles, systems, and methods.

BACKGROUND

Projection systems and components such as illuminators andbeamsplitters, including polarized illuminators and polarizingbeamsplitters, are known. However, many such systems and components arenot designed to provide high efficiency or high brightness in a smallphysical size suitable for use in compact applications, such as wearableor pocket-sized electro-optical devices.

BRIEF SUMMARY

We have developed new families of projection systems, and relatedcomponents such as polarized illuminators and polarizing beamsplitters,that are highly suited for use in compact applications. In some cases,miniaturization is enabled or promoted by the use of a folded opticalpath, as provided in a reflective cavity or a beamsplitter. In somecases, miniaturization is promoted by the use of an illumination beamthat converges at the location where it impinges upon a spatial lightmodulator. In some cases, miniaturization is promoted by the use of abeamsplitter that comprises opposed prisms of substantially differentsizes. In some cases, miniaturization is promoted by beamsplitters whoseobliquely disposed partial reflector defines a first rectangularreference space, and where at least a portion of a light source or atleast a portion of a projector lens is disposed within such firstrectangular reference space. In some cases, miniaturization isexemplified by systems in which a ratio of areas of the firstrectangular reference space and a second rectangular reference space iswithin a range from 30% to 70%, where the second rectangular referencespace is just large enough to encompass the optical components of theprojector. In some cases, miniaturization is promoted by the use ofprojector lens that is small compared to the spatial light modulator,e.g., a lateral dimension of the projector lens, and/or one or more ofits individual lenses, may be no more than 30% or 50% or 70% of thecorresponding lateral dimension of the spatial light modulator.

We disclose for example compact projectors that include a beamsplitter,a light source, a spatial light modulator, and a projector lens. Thebeamsplitter includes a reflective polarizer, the reflective polarizerobliquely disposed to define a diagonal of a first rectangular referencespace. The light source is disposed proximate the reflective polarizerand is configured to emit an input light beam towards the reflectivepolarizer. The spatial light modulator is disposed to receive an outputillumination beam derived from the input light beam, the spatial lightmodulator adapted to selectively reflect the output illumination beam toprovide a patterned light beam, which the projector lens is adapted toreceive. The beamsplitter, the light source, the spatial lightmodulator, and the projector lens are encompassed by a secondrectangular reference space. The first rectangular reference space hasan area Al and the second rectangular reference space has an area A2,and 30%<Al/A2<70%.

We disclose projectors that include a reflective polarizer, a lightsource, a spatial light modulator, and a projector lens. The reflectivepolarizer is obliquely disposed to define a diagonal of a firstrectangular reference space. The light source is disposed proximate thereflective polarizer and is configured to emit an input light beamtowards the reflective polarizer. The spatial light modulator isdisposed to receive an output illumination beam derived from the inputlight beam, and adapted to selectively reflect the output illuminationbeam to provide a patterned light beam. The projector lens is adapted toreceive the patterned light beam. At least a portion of the lightsource, or at least a portion of the projector lens, is disposed withinthe first rectangular reference space.

We disclose beamsplitters that include a first prismatic body comprisinga first prism, a second prismatic body comprising a second prism, and areflective polarizer sandwiched between the first and second prismaticbodies. The first prism is substantially smaller than the second prism.

We disclose illuminators that include a reflector and a reflectivepolarizer disposed to form a reflective cavity with the reflector. Theilluminators also include a retarder film disposed within the reflectivecavity, and a light source disposed to emit a polarized input light beaminto the reflective cavity through an aperture in the reflector. Thereflector, the reflective polarizer, and the retarder film areconfigured to produce an output illumination beam from the input lightbeam, and the output illumination beam is polarized.

We disclose illuminators that include a reflector, a reflectivepolarizer disposed obliquely relative to the reflector, and a retarderfilm disposed between the reflector and the reflective polarizer, and alight source disposed to emit an input light beam of a firstpolarization state through the reflective polarizer towards thereflector. The reflector, the reflective polarizer, and the retarderfilm are configured to produce an output illumination beam from theinput light beam, and the output illumination beam has a secondpolarization state orthogonal to the first polarization state.

We also disclose projectors that include the foregoing illuminators.

Related methods, systems, and articles are also discussed.

These and other aspects of the present application will be apparent fromthe detailed description below. In no event, however, should the abovesummaries be construed as limitations on the claimed subject matter,which subject matter is defined solely by the attached claims, as may beamended during prosecution.

BRIEF DESCRIPTION OF DRAWINGS

The inventions will now be described with reference to the followingfigures, in which:

FIG. 1 is a schematic top view of a compact projection system;

FIG. 2 is a schematic front view of a reflector used in the projectionsystem of FIG. 1;

FIG. 3 is a schematic front view of a spatial light modulator used inthe projection system of FIG. 1;

FIG. 4 is a schematic side view of a portion of a compact projectionsystem, wherein the compact illuminator comprises a “solid cavity” typereflective cavity;

FIG. 5 is a schematic side view of a portion of a compact projectionsystem, wherein the compact illuminator comprises a “hollow cavity” typereflective cavity;

FIG. 6A is a schematic perspective view of an optical body for use as areflective cavity of a compact illuminator, and FIGS. 6B, 6C, and 6D areschematic rear, side, and top views of the optical body;

FIG. 7 is a schematic side view of another compact projection system;

FIG. 8 is a schematic side view of an optical body for use as areflective cavity of a compact illuminator, where one surface isroughened to promote light scattering and make the output illuminationbeam more spatially uniform;

FIG. 9A is a graph of irradiance versus position at the output plane ofthe illumination beam, where the surface roughness provides a Gaussianscattering angle of 0.01 degrees;

FIG. 9B is a graph similar to that of FIG. 9A, but where the surfaceroughness provides a Gaussian scattering angle of 0.1 degrees;

FIG. 9C is a graph similar to that of FIG. 9A, but where the surfaceroughness provides a Gaussian scattering angle of 1 degree;

FIG. 9D is a graph similar to that of FIG. 9A, but where the surfaceroughness provides a Gaussian scattering angle of 2 degrees;

FIG. 9E is a graph similar to that of FIG. 9A, but where the surfaceroughness provides a Gaussian scattering angle of 4 degrees;

FIG. 10A is a duplicate of FIG. 9C;

FIG. 10B is a graph similar to that of FIG. 9A, but where the reflectivecavity utilizes a hollow cavity, and the surface roughness provides aGaussian scattering angle of 1 degree;

FIG. 11 is a schematic top or side view of another compact projectionsystem, this projector having an illuminator that uses a polarizingbeamsplitter of substantially different prism sizes;

FIG. 11A is the same schematic view as FIG. 11, but with two rectangularreference spaces superimposed on the projector;

FIG. 11B is the same schematic view as FIG. 11, but with on-axis andoff-axis image rays of a pass polarization state drawn to show theirpropagation through the system;

FIG. 11C is the same schematic view as FIG. 11, but with on-axis andoff-axis image rays of a block polarization state drawn to show theirpropagation through the system;

FIG. 12 is a schematic top or side view of another compact projectionsystem, this projector also having an illuminator that uses a polarizingbeamsplitter of substantially different prism sizes;

FIG. 13 is a schematic top or side view of another compact projectionsystem, this projector also having an illuminator that uses a polarizingbeamsplitter of substantially different prism sizes;

FIG. 14 is a schematic top or side view of another compact projectionsystem, this projector having an illuminator that uses both a reflectivecavity and a polarizing beamsplitter of substantially different prismsizes;

FIG. 14A is a magnified schematic view of the reflecting layer and theretarding layer on the outer surface of the optical body in FIG. 14;

FIG. 14B is the same schematic view as FIG. 14, but with two rectangularreference spaces superimposed on the projector;

FIG. 15 is a schematic top or side view of another compact projectionsystem, this projector having an illuminator that uses both a reflectivecavity and a polarizing beamsplitter, the projection system alsoincluding a detector device;

FIG. 15A is the same schematic view as FIG. 15, but with two rectangularreference spaces superimposed on the projector; and

FIG. 16 is a schematic side view of another projection system.

In the figures, like reference numerals designate like elements.

DETAILED DESCRIPTION OF ILLUSTRATIVE EMBODIMENTS

As mentioned above, we have developed new families of projection systemsand components thereof that are well suited to miniaturization. Thesesystems and components may use one or more of the following features: afolded optical path, as in a reflective cavity or a (e.g. polarizing)beamsplitter; an illumination beam that is converging at the place whereit impinges upon the spatial light modulator; a beamsplitter that usesopposed prisms of substantially different sizes; a beamsplitter whoseobliquely disposed partial reflector defines a first rectangularreference space, and where at least a portion of the light source or atleast a portion of the projector lens is disposed within such firstrectangular reference space; a system in which a ratio of areas of thefirst rectangular reference space and a second rectangular referencespace is within a range from 30% to 70% or 40% to 70%, where the secondrectangular reference space is just large enough to encompass theoptical components of the projector such as a beamsplitter, the lightsource, the spatial light modulator, and the projector lens; a system inwhich the projector lens is small compared to the active area of thespatial light modulator, e.g., a lateral dimension of the projectorlens, and/or one or more of its individual lenses, may be no more than30% or 50% or 70% of the corresponding lateral dimension of the spatiallight modulator; a system in which the collection efficiency of theprojector lens is substantially uniform over the area of the spatiallight modulator.

Turning then to FIG. 1, we see there a schematic top view of a compactprojector 110. For reference purposes, the projector 110 is drawn in thecontext of a Cartesian x-y-z coordinate system, where it is assumed thatthe x-z plane defines a horizontal plane and the y-axis is a verticalaxis, but other conventions may also be used. The projector 110 includesan illuminator 140, a spatial light modulator 150, and a projector lens160. The z-axis of the coordinate system is assumed to be parallel to anoptical axis 142 of the projector 110 and its component parts. Theilluminator 140 produces an output illumination beam 172 that impingesupon the spatial light modulator 150. In exemplary embodiments, theoutput illumination beam 172 is substantially spatially uniform over theentire active area of such modulator 150, so that the brightness of theprojected image is also substantially uniform. A conventional electroniccontroller (not shown) couples to the spatial light modulator 150 andcontrols the states of the individual elements (pixel elements) 152 inan image-wise fashion. The pixel elements 152 are usually arranged in agrid of rows and columns to provide a rectangular active area. A givenpixel element 152 may have two states—“on” or “off”, as in the case of amonochrome display—or it may have red, green, and blue sub-elements toprovide a full color image. Other conventional configurations of thespatial light modulator 150 are also contemplated. In the embodiment ofFIG. 1, the spatial light modulator 150 is a transmissive-typemodulator. The spatial light modulator 150 thus converts the outputillumination beam 172 into a transmitted patterned light beam 174 whichcontains the image-wise or spatially patterned information from theelectronic controller. The modulator 150 may be a non-polarizedtransmissive device, such as a microelectromechanical system (MEMS), orit may be a liquid crystal based modulator. In the latter case, themodulator 150 selectively rotates the polarization of the light exitingthe array of pixels, and further in that case a polarizer (not shown) isinserted into the projector 110 after the spatial light modulator tofilter out “on” pixels from “off” pixels.

The patterned light beam 174 is then intercepted by the projector lens160 to produce a projected output beam 176. The output beam 176 mayproduce a real image, e.g. an image that can be displayed on a physicalsurface or substrate remotely disposed relative to the projector 110, orit may produce a virtual image, e.g. one that may be viewed directly bythe eye of a user. The projector lens 160 typically, but not in allcases, is a module that includes a plurality of individual lensesarranged in series. In the embodiment of FIG. 1, the projector lens 160includes individual lenses 161, 162, 163, 164, and 165. These lenses aredrawn schematically, but the reader will understand that the individuallenses have curved surfaces, suitable thicknesses, and are composed ofsuitable optical glasses or plastics, to provide high quality opticalperformance. In one exemplary embodiment, the projector lens is afive-element module containing five individual lenses as set forth inthe table provided further below. In an alternative embodiment, afour-element projector lens can be obtained by omitting the fifth lens(lens 5) from referenced five-element projector lens. The scale of FIG.1 is accurate in the sense that the projector lens 160, and itsindividual lenses, each have a lateral dimension (e.g. parallel to thex-axis, or parallel to the y-axis, or along a diagonal of the spatiallight modulator 150) that is substantially smaller than a correspondinglateral dimension of the spatial light modulator 150. This is madepossible by the fact that the output illumination beam 172 is aconverging beam. For example, the lateral dimension of the projectorlens 160, and/or one or more of its individual lenses, may be no morethan 30% or 50% or 70% of the corresponding lateral dimension of thespatial light modulator 150. In an exemplary embodiment based on theprojector lens table provided further below, the lateral dimension ofthe (five-element) projector lens is 2.88 mm and the length of thediagonal of the 5:4 spatial light modulator is 6 mm, for a percentage of48%. The lateral dimension of the individual lens closest to the spatiallight modulator is 2.8 mm, for a percentage of 47%.

The purpose of the illuminator 140 is to illuminate the active area ofthe spatial light modulator 150 so that an optical image or pattern canbe produced. In many, but not all, cases, it is desirable for the outputillumination beam 172 to be a converging light beam at the place whereit impinges upon the spatial light modulator 150, as suggested by lightray 144. It is also often desirable for the output illumination beam 172to be relatively uniform in brightness over the active area of thespatial light modulator 150. Furthermore, it is often desirable toaccomplish this illumination in a package that is physically small, andthat uses high efficiency, high brightness light sources in order tokeep heat generation low and device size small. A logical option forhigh efficiency, high brightness sources is one or more discrete, solidstate light sources such as light emitting diodes (LEDs). However, othersuitable light sources can also be used.

In this regard, “light emitting diode” or “LED” refers to a diode thatemits light, whether visible, ultraviolet, or infrared, although in mostpractical embodiments the emitted light will have a peak wavelength inthe visible spectrum, e.g. from about 400 to 700 nm. The term LEDincludes incoherent encased or encapsulated semiconductor devicesmarketed as “LEDs”, whether of the conventional or super radiantvariety, as well as coherent semiconductor devices such as laser diodes,including but not limited to vertical cavity surface emitting lasers(VCSELs). An “LED die” is an LED in its most basic form, i.e., in theform of an individual component or chip made by semiconductor processingprocedures. For example, the LED die may be formed from a combination ofone or more Group III elements and of one or more Group V elements(III-V semiconductor). The component or chip can include electricalcontacts suitable for application of power to energize the device.Examples include wire bonding, tape automated bonding (TAB), orflip-chip bonding The individual layers and other functional elements ofthe component or chip are typically formed on the wafer scale, and thefinished wafer can then be diced into individual piece parts to yield amultiplicity of LED dies. The LED die may be configured for surfacemount, chip-on-board, or other known mounting configurations. Somepackaged LEDs are made by forming a polymer encapsulant over an LED dieand an associated reflector cup. Some packaged LEDs also include one ormore phosphor materials that are excited by an ultraviolet or shortwavelength visible LED die, and fluoresce at one or more wavelengths inthe visible spectrum. An “LED” for purposes of this application shouldalso be considered to include organic light emitting diodes, commonlyreferred to as OLEDs.

At the heart of the illuminator 140 is a light source 120, which mayinclude one or more LEDs, including in some cases one or more laserdiodes. Several such LEDs can be combined to produce a desired spectraldistribution of light. For example, the outputs of red-, green-, andblue-emitting LEDs may be combined to provide nominally white light, orwhite-emitting LEDs may be used instead or additionally. Alternatively,one or more LEDs of a specific non-white color may be used to producecolored (non-white) illumination, e.g., red, or green, or blueillumination, in which case the projected image will be monochromerather than full color. In the schematic drawing of FIG. 1, the lightsource 120 is drawn as a single LED die 122 disposed behind a polarizer124. The light source 120 is assumed to emit white light, as in the casewhere the LED die emits blue or UV light and is covered with a thincoating (not shown) of a yellow- or white-emitting phosphor. Thepolarizer 124, which may be any suitable polarizer including anabsorbing linear polarizer, a multilayer polymeric reflective polarizer,or a laminate of a reflective polarizer and an absorbing polarizer,predominantly transmits only one polarization state of light, causingthe light emitted by the source 120 to be polarized. In alternativeembodiments, a light guide, lens, or color combiner may be insertedbetween the LED die 122 and the polarizer 124 to allow the LED die (orother active light source, if desired) to be mounted remotely from thepolarizer. In other alternative embodiments, the polarizer 124 may beomitted, such that the light emitted by the source 120 is unpolarized.In still other cases, the polarizer 124 may be retained and a retarderfilm, such as a quarter wave retarder, may be added atop the polarizer124 such that the source 120 emits rotationally polarized (circularly orelliptically polarized) light. However, in the particular embodimentshown in FIG. 1, the light source 120 emits polarized light because thepolarizer 124 is included in front of the LED die 122. The arrow 170schematically represents an input light beam emitted by the light source120 into a reflective cavity, which is also part of the illuminator 140and is discussed further below. The input light beam 170 is assumed tocomprise broad band (and polarized) white light, and is assumed to covera distribution of propagation directions, e.g. in a Gaussiandistribution of angles centered about the optical axis 142. Forillustrative purposes, a representative light ray 144 is shownoriginating from the light source 120 and propagating through theprojector 110. A first ray portion 144 a is part of the input light beam170, and it is shown to have a polarization state P1 as a result of thepolarizer 124.

The input light beam 170 is emitted into a reflective cavity 130 formedby a reflective polarizer 134 and a reflector 132. The reflector 132 hasa high specular reflectivity (for example, in some cases at least 70%,or at least 80%, or at least 90%, or at least 95%) for light within thespectral range of the input light beam 170, and for all polarizationstates, and in some cases it also substantially preserves the degree ofthe polarization of an incident light ray in the reflected ray. Anyknown structure or material that can supply these characteristics can beused. Metal coatings, optically enhanced metal coatings, multilayerinterference structures or films, whether stacks of alternatinginorganic materials, or stacks of coextruded polymers appropriatelyoriented or processed to provide a high reflectivity over a range ofangles and over the spectral range of interest and for allpolarizations, may be used for this purpose. See for example

U.S. Pat. No. 5,882,774 (Jonza et al.). Alternatively, a simple metalcoating such as a layer of aluminum or a layer of silver may in somecases be used for the reflector 132. The reflective polarizer 134provides a high reflectivity (for example, in some cases at least 70%,or at least 80%, or at least 90%) for one polarization state of lightwithin the spectral range of interest, while also providing a lowreflectivity (for example, in some cases less than 30%, or less than20%, or less than 10%) and corresponding high transmission for light ofan orthogonal polarization state in such spectral range. Any knownstructure or material that can supply these characteristics can be used.A wire grid polarizer, cholesteric reflective polarizer, or multilayerpolymeric reflective polarizing film (comprising an interference stackof coextruded polymers appropriately oriented or processed to provide ahigh reflectivity for one polarization state and low reflectivity for anorthogonal polarization state) may be used for the reflective polarizer134. As a specific example, Advanced Polarizer Film (APF) available from3M Company, St. Paul, Minn. may be used for the reflective polarizer134. Given an appropriate reflector 132 and reflective polarizer 134,light of one polarization state can reflect back and forth within thereflective cavity 130 as illustrated by the light ray 144. In theembodiment illustrated, the reflective polarizer 134 is oriented toprovide high reflectivity for light of the first polarization state P1,and thus it will provide low reflectivity and high transmission forlight of an orthogonal second polarization state P2.

In order for the polarized light emitted by the light source 120 toemerge from the illuminator 140, the polarization state should berotated from the first polarization state P1 (which is highly reflectedby the reflective polarizer 134) to the orthogonal second polarizationstate P2 (which is highly transmitted by the reflective polarizer 134).To accomplish this rotation, we include a retarder film 136 in thereflective cavity 130. The retarder film 136 may be located near, andmay be substantially coextensive with, the reflector 132 as shown in thefigure, but the retarder film 136 may alternatively be located elsewherein the reflective cavity 130. The amount of retardation provided by theretarder film 136 is selected to provide the desired rotation of thepolarization state based on the number of passes of a representativelight ray through the retarder film. In the depicted embodiment, lightpasses through the retarder film two times, which would lead one toselect a (single-pass) retardance of a quarter-wave of light for theretarder film 136. Thus, in reference to the light ray 144, uponreflection at the reflective polarizer 134, the first polarization stateP1 is maintained in the reflected ray portion 144 b. This ray portion144 b passes through the retarder film 136, and is reflected at thereflector 132. The resulting reflected ray portion 144 c passes againthrough the retarder film 136, after which it acquires the secondpolarization state P2 (orthogonal to the state P1) as a result of thetwo passes through the retarder film. This ray portion 144 c is thushighly transmitted by the reflective polarizer 134 and emerges from theilluminator 140 as ray portion 144 d, still having the secondpolarization state P2. The ray portion 144 c is one of the many lightrays that make up the output illumination beam 172 discussed above.

The reflector 132 and the reflective polarizer 134 may have the same orsimilar lateral dimensions, e.g., parallel to the x-axis, or parallel tothe y-axis, or along a diagonal of the spatial light modulator 150.Furthermore, the reflector 132 and reflective polarizer 134 may beshaped to have convex or concave curvatures as appropriate to focus thelight from the light source to produce an output illumination beam 172that is converging at the place where such beam impinges on the spatiallight modulator 150. One example of such curvatures is illustrated inFIG. 1. The curvatures may be simple spherical curvatures, or they maybe aspherical. The curvatures may also in some cases be anamorphic,i.e., more highly or strongly curved in one plane (e.g. the y-z plane)than in an orthogonal plane (e.g. the x-z plane). In other cases thecurvatures may be rotationally symmetric about the optical axis 142.

In order for light from the light source 120 to enter the reflectivecavity 130, an aperture 138 is provided in the reflector 132. Note,however, that a light ray within the input light beam 170 that travelsparallel to the optical axis 142 (as well as light rays within a narrowangular cone centered about the optical axis 142) will be reflected bythe reflective polarizer 134 but then will not be reflected by thereflector 132 due to the absence of the refletor 132 in the region ofthe aperture 138, and such light therefore also will not become part ofthe output illumination beam 172. This may give rise to a darkened areain the vicinity of the optical axis 142 in the output illumination beam172, at the position of the spatial light modulator 150, such darkenedarea roughly analogous to a shadow of the aperture 138. To reduce thisshadowing effect, it is helpful to make the aperture 138, as well as thelight source 120, as small as possible.

One or more scattering elements may also be included in the illuminator140 to help further reduce the shadowing effect and make the outputillumination beam 172 more spatially uniform. One example of such ascattering element is a grooved, textured, or otherwise roughenedsurface included as part of the reflective cavity 130. To the extent thereflective cavity 130 makes uses of lenses or other optical bodies towhich the various reflectors or films are applied, such optical bodiesmay be made by single point diamond turning, where the tooling patterncreates a series of grooves that scatter a fraction of the incidentlight toward the optical axis 142. Another example of a scatteringelement is a layer of scattering material that is disposed within thereflective cavity 130. Such a layer may for example be or comprise amicroparticle filled adhesive layer of film, and/or a microstructuredsurface coated with a layer of a different refractive index. Regardlessof which type of scattering element is used, it or they shouldsubstantially preserve the polarization state of light so as not todetract from the operation of the illuminator as already described. Insome cases, the scattering element(s) may provide a spatially uniformscattering, i.e., a scattering that is the same as a function of theradial distance from the optical axis 142.

In other cases, the scattering element(s) may be designed to provide aspatially non-uniform scattering, e.g., a maximum amount of scatteringat or near the optical axis 142, and reduced scattering at increasedradial distances from the optical axis 142.

By inspection of FIG. 1, one can see that it is important to preservethe polarization state of light propagating within the reflective cavity130—except, of course, for the deliberate change in polarization causedby the retarder film 136. If a lens or other optical body substantiallyfilled the space between the reflector 132 and the reflective polarizer134, and if such optical body was made of a material that had a residualoptical birefringence, such residual birefringence could change thepolarization state of a given light ray as it traversed the reflectivecavity 130, such that, for example, the ray portion 144 a was notsubstantially reflected at the reflective polarizer 134, or the rayportion 144 c was not substantially transmitted at the reflectivepolarizer 134. For this reason, it is desirable to substantially fillthe volume of the reflective cavity 130 with a material or medium havinglittle or no birefringence so that proper operation of the illuminator140 can be maintained. In one class of examples, referred to herein as“solid cavity”, a majority of the cavity volume, and in some casessubstantially the entire cavity volume, comprises one or more solidlight-transmissive materials having very low birefringence, such asPMMA, cyclic polyolefins, inorganic glass, or silicones. In anotherclass of examples, referred to herein as “hollow cavity”, a majority ofthe cavity volume, and in some cases substantially the entire cavityvolume, comprises air or vacuum. Some advantages of the hollow cavityapproach include no measurable birefringence, reduced weight, andimproved masking of the shadowing effect, as discussed further below.

In the embodiment of FIG. 1, the aperture 138 is provided not only inthe reflector 132 but also in the retarder film 136. Because of this, asthe light ray 144 travels from the light source 120 to the spatial lightmodulator 150, it passes through the retarder film 136 exactly twotimes. In an alternative embodiment, the aperture in the retarder film136 could be omitted, such that the retarder film 136 was intact andcontinuous, with no central hole. In that case, the light ray 144 wouldpass through the retarder film 136 once in the ray portion 144 a, andonce again in the ray portion 144 b and again in the ray portion 144 c,for a total of three passes through the retarder film 136. Theperformance of such an embodiment may not be optimal but may be adequatefor some applications. The single pass retardation of the retarder film136 in such embodiments would be selected to provide the desiredrotation of the polarization state based on three passes of arepresentative light ray through the retarder film, which would give aresult somewhat less than a quarter-wave of light.

FIG. 2 is taken from a different perspective to illustrate possibleouter boundaries or shapes of the reflective cavity 130 and itsconstituent parts. In particular, FIG. 2 is a front view of a reflector232 which may be the same as or similar to reflector 132, the reflector232 being a part of a projector that may be the same as or similar tothe projector 110 already described. An aperture 238 is provided in thereflector 232, the aperture 238 likewise being the same as or similar tothe aperture 138 in FIG. 1. From the perspective of FIG. 2, the entireaperture can clearly be seen. The aperture 238 is typically but notnecessarily centered on an optical axis 242 of the reflective cavity. Insome cases, the reflector 232 may have a round (circular) outer boundaryor edge 232 a as would be typical for a conventional round lens. Inother cases, the projector size and weight may be decreased bytruncating the reflector 232 to have a reduced boundary or edge 232 b.The boundary 232 b drawn in FIG. 2 is a rectangle whose aspect ratio isabout 5:4. This 5:4 aspect ratio is intended to substantially match theaspect ratio of the active area of the spatial light modulator 150 forefficient matching of the illumination optics to the spatial lightmodulator, although the actual length and width dimensions of thereflector 232 may be somewhat larger than those of the spatial lightmodulator. Note that although only the reflector 232 is depicted in FIG.2, the other chief components of the reflective cavity 130, such as thereflective polarizer 134 and the retarder film 136, may be provided withboundaries or edges that match or substantially match that of thereflector 232, e.g., edge 232 a or edge 232 b.

FIG. 3 schematically illustrates a front view of a spatial lightmodulator 350, which may be the same as or similar to the spatial lightmodulator 150 in FIG. 1. Alternatively, the spatial light modulator 350may represent a reflective-type spatial light modulator, as discussed insome of the embodiments below. The active area of the modulator 350 isfilled with rows and columns of individual pixel elements 352, only someof the rows and columns being shown in FIG. 3 for simplicity. The lengthand width of the active area is typically substantially rectangular, andthe rectangle often has a length-to-width aspect ratio of 5:4. Ofcourse, other aspect ratios may be used, but it is sometimes desirableto match the relative shape (e.g. as characterized by an aspect ratio)of the illumination optics to that of the spatial light modulator. Anelectronic controller couples to the spatial light modulator 350 andcontrols the states of all of the individual pixels, as explained above.The spatial light modulator 350 may be configured such that thedifference between “on” pixels and “off” pixels is given by a rotationin the polarization of the outgoing light ray, and/or an angulardeflection of the outgoing light ray.

FIG. 4 illustrates a portion of a compact projection system including acompact illuminator, the illuminator comprising a “solid cavity” typereflective cavity as explained above. Thus, in FIG. 4, an illuminator440 includes a light source 420 and a reflective cavity 430. The lightsource 420 includes an LED die 422 and a polarizer 424, but the lightsource 420 may alternatively be or comprise any of the variationsdiscussed above with regard to light source 120. The illuminator 440 andlight source 420, as well as a spatial light modulator 450 (having pixelelements 452), are arranged along an optical axis 442.

The light source injects an input light beam 470 into the reflectivecavity 430, which is defined by a reflective polarizer 434 and areflector 432. Disposed within the reflective cavity is a retarder film436. The retarder film 436 is located adjacent the reflector 432, and anaperture 438 is provided in both the reflector and the retarder film.Light from the polarized light source 420 exits the reflective cavity430 as output illumination beam 472, which illuminates the active areaof the spatial light modulator 450. The spatial light modulator 450converts the beam 472 into a transmitted patterned light beam 474, thebeam 474 containing image-wise or spatially patterned information. Allof the foregoing elements of the embodiment of FIG. 4 may be the same asor similar to the corresponding elements discussed above in connectionwith FIG. 1, and the embodiment of FIG. 4 may be used in a projector thesame as or similar to that of FIG. 1. Similarly, the manner in whichpolarized light from the light source 420 reflects back and forth withinthe cavity 430, and its polarization rotated to allow it to emerge asoutput illumination beam 472, is the same as or similar to the operationof the illuminator 140, and need not be repeated here.

However, the particular construction of the reflective cavity 430 isworthy of some additional observations. The space between the reflector432 and the reflective polarizer 434 defines a cavity volume, andsubstantially all of that cavity volume is occupied by one or more solidlight-transmissive materials, in particular, a first optical lens orbody 431 and a second optical lens or body 433. The bodies 431, 433 arecemented together along an interface 435 with a suitable opticaladhesive or other optical bonding material. For ease of manufacture theinterface 435 may be planar. The bodies 431, 433 are composed ofsuitable very low birefringence optical materials as discussed in moredetail above, and they may be composed of different such opticalmaterials or the same optical material. In an alternative embodiment thetwo optical bodies 431, 433 may be replaced with a single unitaryoptical body without any interface 435 therein but having the same outersurfaces. The optical body 431 has an outer curved surface 431 a towhich the retarder film 436 is applied directly or by a suitable opticalbonding material. The reflector 432 is applied atop the retarder film sothat the retarder film is properly positioned between the reflector 432and the reflective polarizer 434. The reflective polarizer 434, in turn,is applied to an outer curved surface 433 a of the optical body 433.Central portions of the reflector 432 and the retarder film 436 areetched, cut, or otherwise omitted to define the aperture 438, which isappropriately sized to the light source 420. At the aperture 438, theouter surface 431 a of the optical body 431 may be exposed.

FIG. 5 illustrates a portion of a compact projection system similar toFIG. 4, but for the opposite case in which the illuminator comprises ahollow cavity type reflective cavity rather than a solid cavity. Thus,in FIG. 5, an illuminator 540 includes a light source 520 and areflective cavity 530. The light source 520 includes an LED die 522 anda polarizer 524, but the light source 520 may alternatively be orcomprise any of the variations discussed above with regard to lightsource 120. The illuminator 540 and light source 520, as well as aspatial light modulator 550 (having pixel elements 552), are arrangedalong an optical axis 542. The light source injects an input light beam570 into the reflective cavity 530, which is defined by a reflectivepolarizer 534 and a reflector 532. Disposed within the reflective cavityis a retarder film 536. The retarder film 536 is located adjacent thereflector 532, and an aperture 538 is provided in both the reflector andthe retarder film. Light from the polarized light source 520 exits thereflective cavity 530 as output illumination beam, which illuminates theactive area of the spatial light modulator 550. The spatial lightmodulator 550 converts the illumination beam into a transmittedpatterned light beam 574, the beam 574 containing image-wise orspatially patterned information. All of the foregoing elements of theembodiment of FIG. 5 may be the same as or similar to the correspondingelements discussed above in connection with FIG. 1, and the embodimentof FIG. 5 may be used in a projector the same as or similar to that ofFIG. 1. Similarly, the manner in which polarized light from the lightsource 520 reflects back and forth within the cavity 530, and itspolarization rotated to allow it to emerge as an output illuminationbeam, is the same as or similar to the operation of the illuminator 140,and need not be repeated here.

However, the particular construction of the reflective cavity 530 isworthy of some additional observations. The space between the reflector532 and the reflective polarizer 534 defines a cavity volume, andsubstantially all of that cavity volume is occupied by air, or vacuum,rather than any solid light-transmissive materials. This is madepossible by supporting the opposed reflectors and retarder film on theinward-facing major surfaces of two optical bodies that are spaced apartfrom each other. In particular, a first optical lens or body 531 has acurved major surface 531 a that faces a second optical lens or body 533,and the second body 533 has a curved major surface 533 a that faces thefirst body 531. The bodies 531, 533 may be held firmly and stably intheir relative positions by a suitable substrate or framework attachedto the outer edges of the bodies. The bodies 531, 533 may be composed ofsuitably transparent optical materials to allow light from the lightsource 520 to pass through the body 531, and light exiting thereflective cavity 530 to pass through the body 533. The bodies 531, 533may also be composed of relatively low birefringence optical materialsso that the polarization state of light passing through the body 531, aswell as the polarization state of light passing through the body 533, isnot significantly rotated. But the amount of birefringence that can betolerated in the bodies 531, 533 is substantially greater than that ofbodies 431, 433, due to the substantially shorter optical path lengthsfor light rays passing through the bodies 531, 533 than for light rayspassing through bodies 431, 433. This is a result of being able todesign the bodies 531, 533 to have thicknesses (the dimension measuredalong the z-axis) that are substantially less than the on-axis thicknessof the reflective cavity 530. The optical body 531 has an inner curvedsurface 531 a to which the reflector 532 is applied directly or by asuitable optical bonding material. The retarder film 536 is applied atopthe retarder film so that the retarder film is properly positionedbetween the reflector 532 and the reflective polarizer 534 when theoptical bodies 531, 533 are properly mounted. The reflective polarizer534, in turn, is applied to an inner curved surface 533 a of the opticalbody 533. Central portions of the reflector 532 and the retarder film536 are etched, cut, or otherwise omitted to define the aperture 538,which is appropriately sized to the light source 520. At the aperture538, the inner surface 531 a of the optical body 531 may be exposed.

Some advantages of hollow cavity-type illuminators may include one ormore of: reduced weight; no measurable birefringence in the reflectivecavity, including no birefringence resulting from thermally inducedstress, as may occur in a solid optical body; the curved surfaces 531 a,533 a can be formed in thin substrates by microreplication, reducingstray birefringence concerns and reducing any absorptive losses; andimproved masking of the shadowing effect, i.e., improved spatialuniformity of the output illumination beam, as demonstrated below inconnection with FIGS. 10A and 10B.

FIGS. 6A through 6D illustrate various views of a particular opticalbody 637 that has been found to be useful in at least some of thedisclosed compact illuminators and projectors. FIG. 6A is a perspectiveview, FIG. 6B is a rear view, FIG. 6C is a side view, and FIG. 6D is atop view of the optical body 637. The FIGS. 6A-6D are at leastapproximately to scale with regard to relative lengths, widths, andthicknesses of the various illustrated features. The optical body 637 iscomposed of a first optical body 631 attached to a second optical body633 along a planar interface 635. The bodies 631, 633 are analogous tothe optical bodies 432, 433 of FIG. 4, and those optical bodies of FIG.4 can be designed precisely as set forth here in connection with theoptical body 637.

The first and second optical bodies 631, 633 are assumed to be made ofthe same very low birefringence optical material, in particular,annealed PMMA, which has a refractive index of about 1.49 at a visiblewavelength of 550 nm. The first optical body 631 has an outer majorconvex surface 631 a and the second optical body 633 has an outer majorconcave surface 633 a, and both of these surface curvatures are orientedalong the same optical axis 642 of the optical body 637. These twosurface curvatures are each also aspherical, but are rotationallysymmetric about the optical axis 642 (ignoring the rectangular outerboundary or edge of the bodies 637, 631, 633).

The surface 631 a has a radius of curvature of 11.156 mm, a conicconstant of 0.11055, and the following polynomial aspheric coefficients:

4^(th) order aspheric coefficient: 0.00012286;

6^(th) order aspheric coefficient: −1.3845E-06; and

8^(th) order aspheric coefficient: 5.2850E-08, where exponentialnotation is used for numbers of very small magnitude. The asphericcoefficients and other information relating to the curvature of surfaces631 a (and 633 a) is provided herein using the nomenclature ofLightTools™ illumination design software.

The surface 633 a has a paraxial radius of curvature of 58.562 mm, aconic constant of 29.052, and the following polynomial asphericcoefficients:

4^(th) order aspheric coefficient: 2.2997E-05;

6^(th) order aspheric coefficient: 1.2025E-05; and

8^(th) order aspheric coefficient: 7.0933E-08.

The overall length (dimension along the x-axis) and width (dimensionalong the y-axis) of the optical body 637 and its component bodies 631,633 is 9.2 millimeters and 7.4 millimeters, respectively. The 9.2 mmlength and 7.4 mm width are substantially in the proportion of 5:4. Theaxial thickness of the optical body 637, i.e., the physical thickness(dimension along the z-axis) of the optical body 637 measured at theoptical axis 642, is 4.38 millimeters.

The performance of a compact projection system utilizing the opticalbody 637, in an embodiment similar to that of FIG. 4, was modeled withcommercial optical modeling software. Such modeling is discussed belowin connection with FIGS. 8 and 9A through 9E.

FIG. 7 is a schematic side view of another compact projection system,this one using an illuminator having a hollow cavity type of reflectivecavity similar to FIG. 5. In FIG. 7, a projector includes a compactilluminator 740, a spatial light modulator 750 (having pixel elements752), and a projector lens 760 (a lens module having individual lenses761, 762, 763, 764, and 765). The illuminator 740 includes a lightsource 720 and a reflective cavity 730. The light source 720 includes anLED die 722 and a polarizer 724, but the light source 720 mayalternatively be or comprise any of the variations discussed above withregard to light source 120. The illuminator 740 and light source 720, aswell as the spatial light modulator 750 and the projector lens 760, arearranged along an optical axis 742. The light source injects an inputlight beam 770 into the reflective cavity 730, which is defined by areflective polarizer 734 and a reflector 732. Disposed within thereflective cavity is a retarder film 736. The retarder film 736 islocated adjacent the reflector 732, and an aperture 738 is provided inboth the reflector and the retarder film. Light from the polarized lightsource 720 exits the reflective cavity 730 as output illumination beam,which illuminates the active area of the spatial light modulator 750.The spatial light modulator 750 converts the illumination beam into atransmitted patterned light beam 774, the beam 774 containing image-wiseor spatially patterned information. All of the foregoing elements of theembodiment of FIG. 7 may be the same as or similar to the correspondingelements discussed above in connection with FIGS. 1 and 5. Similarly,the manner in which polarized light from the light source 720 reflectsback and forth within the cavity 730, and its polarization rotated toallow it to emerge as an output illumination beam, is the same as orsimilar to the operation of the illuminator 140. In brief, referring torepresentative light ray 744: a first ray portion 744 a, which is partof the input light beam 770, has a polarization state P1; a second rayportion 744 b is generated by reflection from reflective polarizer 734;a third ray portion 744 c is generated by reflection from reflector 732,and has a rotated second polarization state P2 due to two passes of thelight ray through the retarder film 736; a fourth ray portion 744 d,which is part of the output illumination beam, also has the secondpolarization state P2 and impinges upon the spatial light modulator 750;a fifth ray portion 744 e, which is spatially modulated by the modulator750 as a function of whether the particular pixel 752 through which thebeam passes is in an “on” or “off” state. If we assume the ray portion744 e is passed by the modulator 750, it then goes on to be captured bythe projector lens 760 and emitted to a remote surface or user.

Similar to the embodiment of FIG. 5, the projector and illuminator ofFIG. 7 utilize a hollow cavity type reflective cavity 730. A firstoptical lens or body 731 has a curved major surface 731 a that faces asecond optical lens or body 733, and the second body 733 has a curvedmajor surface 733 a that faces the first body 731. These bodies 731, 733are analogous to the optical bodies 531, 533 described above, except thecurvatures of the respective major surfaces have been changed. Relativeto the FIG. 5 embodiment, the curvature of the surface 731 a has beenreduced (greater radius of curvature), and the curvature of the surface733 a has been flipped from convex to concave. In this regard, there issubstantial design flexibility in selecting the curvatures of thereflectors that form the reflective cavity in the disclosed embodiments(both hollow cavity types and solid cavity types), and even non-curvedor planar shapes can be used. But in many cases it is neverthelessdesirable to select a set of curvatures that will produce anillumination beam that is converging at the place where it impinges uponthe spatial light modulator.

As mentioned above, the performance of a compact projection systemutilizing the optical body 637 was modeled with commercial opticalmodeling software. One added feature that was investigated as part ofthe modeling was the addition of surface roughness on one of the curvedouter surfaces of the optical body, as illustrated generally in FIG. 8,to introduce controlled amounts of light scattering. In that figure, anoptical body 837 is composed of a first optical body 831 and a secondoptical body 833 joined together along a planar interface 835, andaligned along an optical axis 842. The first optical body 831 has anouter curved surface 831 a, and the second optical body 833 has an outercurved surface 833 a. For ease of illustration, a reflector, areflective polarizer, and a retarder film are omitted from FIG. 8, butthe reader will understand that such optical elements are applied to thesurfaces 831 a, 833 a in the same fashion as they are applied to therespective curved surfaces 431 a, 433 a as described above, to form areflective cavity using the optical body 837. Specifically, the retarderfilm and reflector (with suitable apertures) are applied to the curvedsurface 831 a, and the reflective polarizer is applied to the curvedsurface 833 a. A light source 820, having an LED die 822 and a polarizer824, injects an input light beam 870 into the reflective cavity, and anoutput illumination beam 872 emerges from the other side of thereflective cavity to illuminate the spatial light modulator, representedschematically in FIG. 8 by reference number 854. Propagation of lightback and forth within the reflective cavity is substantially asdescribed in FIG. 1.

The optical modeling was able to create a controlled amount of surfaceroughness along the curved surface 831 a, while otherwise maintainingthe original nominal curvature of that surface. The same controlledsurface roughness was also imputed to the reflector (see e.g. reflector432 in FIG. 4), which was assumed to be applied to such surface. Themodeling assumed the curvatures, thicknesses, and material propertiesdiscussed above for the optical body 637 of FIG. 6. The optical modelingalso assumed:

-   -   the reflector (refer again to reflector 432 in FIG. 4) had a        reflectivity of 100% for all polarizations of light;    -   the reflective polarizer (refer e.g. to reflective polarizer 434        in FIG. 4) had a 100% reflectivity for a first polarization        state and 0% reflectivity (100% transmission) for an orthogonal        second polarization state;    -   the size of the aperture (refer e.g. to aperture 438 in FIG. 4)        was 0.3 by 0.5 millimeters;    -   a spatial light modulator having a 5:4 length-to-width aspect        ratio and diagonal measuring 6.0 millimeters;    -   a projector lens module that included five individual lenses        arranged in series as shown in the following table, where lens 1        refers to the individual lens that is farthest from the spatial        light modulator and lens 5 refers to the individual lens that is        closest to the spatial light modulator, where a negative radius        (R1, R2) denotes a concave curvature, a positive radius denotes        a convex curvature, CT denotes center thickness, RICH denotes R1        center height, and DIA denotes the lens diameter:

5-element Projector Lens Details R1 R2 CT R1CH DIA Lens Material (mm)(mm) (mm) (mm) (mm) 1 LAFN21 2.5732 −8.0998 0.6 7.8738 2.8 2 SF5 −9.5469−2.454 0.55 7.0738 2.55 3 SF2 7.6121 −2.8515 0.25 6.2238 2.11 4 NBFD32.8515 5.393 0.75 5.9738 2.06 5 SF5 −26.823 15.894 0.5 4.355 2.88Note from the table that the overall lateral dimension (diameter) of theprojector lens is only 2.88 millimeters, and the diameter of theindividual lens that is nearest the spatial light modulator (lens 1) isonly 2.8 mm.

The optical modeling simulated the distribution of light produced by theoutput illumination beam as imaged by the projector lens onto afar-field detector plane, and calculated the brightness or intensity(irradiance) of that far field image as a function of position. Themodeling was repeated for different amounts of surface roughness on thecurved surface 831 a, and the results are shown in FIGS. 9A through 9E.In FIGS. 9A, 9B, 9C, 9D, and 9E, surface roughnesses corresponding toGaussian diffusion angles of 0.01 degrees, 0.1 degrees, 1 degree, 2degrees, and 4 degrees respectively were assumed. In the figures, thesolid curves 902 a, 902 b, 902 c, 902 d, and 902 e represent thecalculated irradiance-versus-position curves along the horizontal orx-axis in the far-field plane, and the dashed curves 904 a, 904 b, 904c, 904 d, and 904 e represent the calculated irradiance-versus-positioncurves along the vertical or y-axis in the far-field plane. Inspectionand comparison of FIGS. 9A through 9E confirms that increased amounts ofsurface roughness and light scattering yield a more uniform irradiancedistribution and less pronounced dark spot or shadow in the center ofthe image.

The optical modeling software was then used again to establish acomparison between a solid cavity type illuminator and a hollow cavitytype illuminator. The results of FIGS. 9A through 9E all assume a solidcavity type illuminator. We simulated a hollow cavity type illuminatorby programming the modeling software to replace all of the annealed PMMAmaterial within the reflective cavity with air (refractive index=1), butkeeping everything else including the curvatures, distances,reflectivities, and so forth the same. This comparision was done for thecase of a surface roughness corresponding to a Gaussian diffusion angleof 1 degree. The results for the solid cavity type system were shown inFIG. 9C, and are reproduced in FIG. 10A for ease of comparison. Theresults for the corresponding hollow cavity type system are shown inFIG. 10B, where solid curve 1002 b represents the calculatedirradiance-versus-position curves along the horizontal or x-axis in thefar-field plane, and the dashed curve 1004 b represents the calculatedirradiance-versus-position curves along the vertical or y-axis in thefar-field plane. Comparison of FIGS. 10A and 10B confirm the conclusionthat a hollow cavity design for the compact illuminator providesimproved masking of the shadowing effect and improved spatial uniformityof the output illumination beam.

Turning now to FIG. 11, we see there a different type of compactilluminator and projector 1110. Rather than using a reflective cavityconfiguration as depicted in FIG. 1, the projector 1110 uses apolarizing beamsplitter 1180, and the beamsplitter uses opposed prismsof substantially different sizes.

The projector also comprises a light source 1120, which includes an LEDdie 1122 and polarizer 1124, a spatial light modulator 1150 (see FIG.11A), which includes pixel elements 1152, and projector lens 1160, whichincludes individual lenses 1161, 1162, 1163, 1164. The light source,spatial light modulator, and projector lens may be the same as orsimilar to the various light sources, spatial light modulators, andprojectors discussed in the preceding embodiments, except that thespatial light modulator in the projector 1110 is designed to operate inreflection rather than in transmission. As a result, the spatial lightmodulator 1150 may for example be or comprise a Liquid Crystal onSilicon (LCoS) device. Such devices may be flat (as illustratedschematically), or they may include a curved reflector array that iscurved in one or more axes.

The light source 1120 emits a polarized input light beam 1170 into thebeamsplitter 1180 towards an obliquely disposed reflective polarizer1184. The reflective polarizer 1184 may be the same as or similar to thereflective polarizers discussed in the preceding embodiments, exceptthat the reflective polarizer 1184 may if desired by optimized foroblique angle performance and in an immersed configuration (surroundedby solid light-transmissive optical materials such as glass or plastic).The reflective polarizer is sandwiched between two opposed prismaticbodies to form the beamsplitter 1180.

A first such prismatic body 1190 contains two facets 1192 a, 1192 bwhich define a relatively small prism 1192. The input light beam 1170enters the beamsplitter 1180 through the facet 1192 a, and spatiallypatterned light from the spatial light modulator (as explained below)exits the beamsplitter through the facet 1192 b. For size comparisonpurposes, the boundaries of the small prism 1192 can be ascertained byextending the facets 1192 a, 1192 b to the reflective polarizer 1184 todefine the labeled points c and b, respectively. A third point, a, liesat the intersection of the facets 1192 a, 1192 b, at the apex of thesmall prism 1192. The set of points a, b, c may thus be considered todefine the corners of the small prism 1192.

The other prismatic body, opposite the first prismatic body 1190, is arelatively larger prism 1195. The corners of this prism 1195 are clearlyseen as labeled points d, e, and f. Attached to the side surfaces of theprism 1195 are lenses or other optical bodies having exterior curvedsurfaces. In alternative embodiments, one or both of these opticalbodies may be combined with the prism 1195 in a unitary prismatic body.

A reflector 1182 is applied to one of these exterior curved surfaces asshown in FIG. 11, and a retarder film 1186 is disposed between thereflector 1182 and the reflective polarizer 1184. The reflector 1182 maybe the same as or similar to the reflectors 132, 232, 432, 532, 732discussed above, e.g., the reflector 1182 may have a high specularreflectivity (for example, in some cases at least 70%, or at least 80%,or at least 90%, or at least 95%) for light within the spectral range ofthe input light beam 1170, and for all polarization states, and in somecases it also substantially preserves the polarization state of anincident light ray in the reflected ray. The retarder film 1186 may bethe same as or similar to the retarding films discussed in the precedingembodiments.

The light source 1120 in combination with the beamsplitter 1180 servesas an illuminator. As will be described in relation to a representativelight ray 1144, light from the light source 1120 propagates within thebeamsplitter 1180 until it emerges as an output illumination beam 1172.The output illumination beam 1172 illuminates the active area of thespatial light modulator 1150 (see FIG. 11A) so that an optical image orpattern can be produced. In many, but not all, cases, it is desirablefor the output illumination beam 1172 to be a converging light beam atthe place where it impinges on the spatial light modulator 1150. It isalso often desirable for the output illumination beam 1172 to berelatively uniform in brightness over the active area of the spatiallight modulator 1150.

In reference to the light ray 1144, a first ray portion 1144 a is partof the input light beam 1170, which enters the beamsplitter 1180 throughthe facet 1192 a. The ray portion 1144 a is caused by the polarizer 1124to have a second polarization state P2. The reflective polarizer 1184 isconfigured and oriented to highly transmit light of the secondpolarization state P2, and highly reflect light of the orthogonal firstpolarization state P1. Therefore, upon encountering the reflectivepolarizer 1184, the ray portion 1144 a is highly transmitted through thereflective polarizer 1184 into the prism 1195 to become ray portion 1144b, still having the second polarization state P2. The ray then passesthrough the retarder film 1186 to become ray portion 1144 c, isreflected by the reflector 1182 to become ray portion 1144 d, and passesthrough the retarder film 1186 again to become ray portion 1144 e. As aresult of the two passes through the retarder film 1186, the ray portion1144 e has the first polarization state P1, orthogonal to the originalsecond polarization state P2. Upon encountering the reflective polarizer1184, the ray portion 1144 e is highly reflected to become ray portion1144 f, and finally emerging from the lower curved surface of theilluminator as ray portion 1144 g, which can be considered part of theoutput illumination beam 1172.

The spatial light modulator 1150 (see FIG. 11A) is placed in the outputillumination beam 1172 at the output of the illuminator, and itselectively reflects incident light in an image-wise fashion. Forexample, pixel elements 1152 in an “on” state may rotate thepolarization state of the reflected light by 90 degrees, whereas pixelelements 1152 in an “off” state may produce no such polarizationrotation, or vice versa. In either case, the spatial light modulator1150 converts the output illumination beam 1172 into a reflectedpatterned light beam 174 which is transmitted through the samebeamsplitter 1180 , through the facet 1192 b to the projector lens 1160,as explained below. The projector lens 1160 then transforms thereflected patterned light beam into a projected output beam 1176,analogous to the projected output beams discussed in the precedingembodiments.

One can see that, in connection with the operation of the beamsplitter1180, it is again important to preserve the polarization state of lightpropagating within the beamsplitter, except for the deliberate change inpolarization caused by the retarder film 1186. It is therefore desirablefor the solid light-transmissive optical materials that make up theprisms 1192, 1195 and other optical bodies connected thereto to be madeof very low birefringence materials as explained above.

One design feature of the projector 1110 that facilitatesminiaturization is the substantial size disparity of the prisms 1192,1195. By making the prism 1192 substantially smaller than the otherprism, the light source 1120, and/or the projector lens 1160, can bebrought closer to the reflective polarizer 1184, thus reducing theoverall projector size. Note also however that the small prism 1192 neednot be microscopic in size relative to the larger prism; instead, thesmall prism 1192 is large enough so that light that passes through thefirst prismatic body 1190 is predominantly, or mostly, also transmittedthrough the small prism 1192. The relative sizes of the opposed prismscan be characterized in terms of their hypotenuse lengths and/or theirprism heights. The hypotenuse length of the small prism 1192, which wemay call HL1, is the distance between the points b and c, and thehypotenuse length of the other prism 1195, which we may call HL2, is thedistance between the points d and f. The prism heights of the prisms1192, 1195, which we may call H1 and H2, respectively, are illustratedin FIG. 11 as being measured relative to the reflective polarizer 1184.To characterize the size disparities of the opposed prisms, we mayspecify that the ratio HL1/HL2 is in a range from 40% to 70%, and/orthat the ratio H1/H2 is similarly in a range from 40% to 70%.

FIG. 11A is a substantial duplicate of FIG. 11, where like referencenumbers designate like elements with no further need for discussion,except that the reflective spatial light modulator 1150, alreadydescribed above, is now shown in its proper position to intercept theoutput illumination beam 1172. Superimposed on the figure are tworectangular reference spaces 1103, 1105. The first reference space 1103is a rectangular space defined by the obliquely oriented reflectivepolarizer 1184. More specifically, the reference space 1103 is arectangle whose diagonal line is the reflective polarizer 1184. Thisroughly corresponds to the rectangular space occupied by a conventionalbeamsplitter. On the other hand, the second reference space 1105 may bedescribed as the smallest rectangular space that encompasses the opticalcomponents (exclusive of any mechanical mounting hardware or the like)of the projector. For the projector 1110, those optical components arethe beamsplitter 1180, the light source 1120, the spatial lightmodulator 1150, and the projector lens 1160.

As a result of our miniaturization efforts, several new relationshipscan be satisfied by the projector 1110 and/or other disclosedprojectors.

For example, at least a portion of the light source 1120, or at least aportion of the projector lens 1160, are disposed within the firstrectangular reference space 1103. In some cases at least a portion ofthe light source 1120 and at least a portion of the projector lens 1160are both disposed within the first rectangular reference space 1103. Insome cases, at least a portion of the light source, or at least aportion of the projector lens, but not both, are disposed within thefirst rectangular reference space 1103. The first rectangular referencespace 1103 may be split into two portions, along the diagonal of thereflective polarizer 1184. When so split, the at least a portion of thelight source 1120, or the at least a portion of the projector lens 1160,is disposed within one such portion of the first rectangular referencespace 1103. Furthermore, the at least a portion of the light source andthe at least a portion of the projector lens may both be disposed withinsuch portion of the first rectangular reference space 1103. If the lightsource 1120 comprises an LED die 1122, the LED die 1122 may be entirelydisposed within the first rectangular reference space 1103. If theprojector lens 1160 comprises a plurality of individual lenses 1161,1162, 1163, 1164, at least one of the individual lenses may be entirelydisposed within the first rectangular reference space 1103.

Also, the projector can be miniaturized to such an extent that theoptical components of the projector (exclusive of any mechanicalmounting hardware or the like) can fit within a space that is onlyslightly larger than the space occupied by a conventional beamsplitterfor that projector. Stated differently, if Al is the area of the firstrectangular reference space 1103, and A2 is the area of the secondrectangular reference space 1105, then the ratio of A1/A2 may be in arange from 30% to 70%, or from 40% to 70%.

The foregoing relationships relating to reference spaces, locations ofelements within or outside of such spaces, comparisons of areas of suchspaces, and so forth can be ascertained with reasonable accuracy byreference to FIGS. 11 and 11A despite the fact that these figures areschematic in nature. Although schematic, the relative sizes andpositions of pertinent system components in these figures are believedto be reasonably representative of how such components would appear inan actual scale drawing. This can also be said for at least FIGS. 14,14B, 15, and 15A below. Based on FIG. 11A, the ratio of the area ofreference space 1103 to the area of reference space 1105 (A1/A2) is atleast 60%.

FIGS. 11B and 11C are provided to further illustrate the passage oflight through the projector 1110 after the output illumination beam 1172is reflected by the spatial light modulator 1150. FIG. 11B covers thecase of light reflected by “on” pixels of the modulator 1150, whereasFIG. 11C covers the case of light reflected by “off” pixels of themodulator. Otherwise, in these figures, like reference numbers to thosein FIGS. 11 and 11A refer to like elements, and need no furtherexplanation.

In FIG. 11B, light from the output illumination beam 1172 is reflectedby an on-axis pixel 1152 a and by an off-axis pixel 1152 b, both ofthese pixels assumed to be in an “on” state such that the reflectedlight has a rotated polarization, i.e., the reflected light has thesecond polarization state P2 rather than state P1. Light of thispolarization state P2 is highly transmitted by the reflective polarizer1184. Thus, the light reflected by the “on” pixels is transmittedthrough the reflective polarizer 1184 and exits the beamsplitter 1180through the facet 1192 b of the prism 1192, and is collected by theprojector lens 1160 to ultimately form the projected output beam 1176.

On the other hand, in FIG. 11C, light from the output illumination beam1172 is again reflected by the on-axis pixel 1152 a and by the off-axispixel 1152 b, but now these pixels are assumed to be in an “off” statesuch that the reflected light does not have a rotated polarization,i.e., the reflected light has the first polarization state P1. Light ofthis polarization state P1 is highly reflected by the reflectivepolarizer 1184. Thus, the light reflected by the “off” pixels isreflected by the reflective polarizer 1184 and thereafter reflected bythe reflector 1182 towards the left side of the beamsplitter 1180, wheresuch rays may be absorbed or otherwise lost. Light reflected by the“off” pixels thus do not get collected by the projector lens 1160, anddo not substantially contribute to the projected output beam 1176.

FIGS. 12 and 13 represent modifications to the projector 1110, where thefirst prismatic body 1190 is replaced by alternative prismatic bodies.These replacements do not substantially change the manner in which lightpropagates between the light source, spatial light modulator, andprojection lens, and thus that description will not be repeated forthese figures.

In FIG. 12, a projector 1210 uses a polarizing beamsplitter 1280 havingopposed prisms of substantially different sizes. The projector 1210 alsocomprises a light source 1220, a spatial light modulator 1250 whichincludes pixel elements 1252, and a projector lens 1260 which includesindividual lenses, and all of these elements may be the same as orsimilar to corresponding elements in the projector 1110.

The beamsplitter 1280 includes an obliquely disposed reflectivepolarizer 1284 sandwiched between two opposed prismatic bodies: a firstsuch prismatic body 1290 contains two facets 1292 a, 1292 b which definea relatively small prism 1292, and the other prismatic body is arelatively larger prism 1295. Polarized light from the light source 1220enters the beamsplitter 1280 through the facet 1292 a, and spatiallypatterned light from the spatial light modulator 1250 exits thebeamsplitter through the facet 1292 b. The boundaries of the small prism1292 can be ascertained by extending the facets 1292 a, 1292 b to thereflective polarizer 1284 to define the labeled points c and b,respectively, and a third point, a, lies at the intersection of thefacets 1292 a, 1292 b. The corners of the larger prism 1295 are clearlyseen as labeled points d, e, and f. Attached to the side surfaces of theprism 1295 are lenses or other optical bodies having exterior curvedsurfaces. A reflector 1282 is applied to one of these exterior curvedsurfaces, and a retarder film 1286 is disposed between the reflector1282 and the reflective polarizer 1284. The reflector 1282 and retarderfilm 1286 may be the same as or similar to corresponding elements of theprojector 1110. The light source 1220 in combination with thebeamsplitter 1280 serves as an illuminator. Light that is reflected by“on” pixels of the spatial light modulator is transmitted through thereflective polarizer 1284 and exits the beamsplitter 1280 through thefacet 1292 b of the prism 1292, and is collected by the projector lens1260 to ultimately form the projected output beam 1276.

In this embodiment, the first prismatic body 1290 covers only a portionof the reflective polarizer 1284, and the first prismatic body 1290comprises no prisms other than the prism 1292. The locations of thepoints a, b, c, d, e, f may be substantially the same as correspondingpoints in the projector 1110, hence, the prism dimensions H1, H2, HL1,and HL2, and their various ratios may satisfy the same conditions asdiscussed above.

In FIG. 13, a projector 1310 uses a polarizing beamsplitter 1380 havingopposed prisms of substantially different sizes. The projector 1310 alsocomprises a light source 1320, a spatial light modulator 1350 whichincludes pixel elements 1352, and a projector lens 1360 which includesindividual lenses, and all of these elements may be the same as orsimilar to corresponding elements in the projector 1110.

The beamsplitter 1380 includes an obliquely disposed reflectivepolarizer 1384 sandwiched between two opposed prismatic bodies: a firstsuch prismatic body 1390 contains two facets 1392 a, 1392 b which definea relatively small prism 1392, and the other prismatic body is arelatively larger prism 1395. Polarized light from the light source 1320enters the beamsplitter 1380 through the facet 1392 a, and spatiallypatterned light from the spatial light modulator 1350 exits thebeamsplitter through the facet 1392 b. The boundaries of the small prism1392 can be ascertained by extending the facets 1392 a, 1392 b to thereflective polarizer 1384 to define the labeled points c and b,respectively, and a third point, a, lies at the intersection of thefacets 1392 a, 1392 b. The corners of the larger prism 1395 are clearlyseen as labeled points d, e, and f. Attached to the side surfaces of theprism 1395 are lenses or other optical bodies having exterior curvedsurfaces. A reflector 1382 is applied to one of these exterior curvedsurfaces, and a retarder film 1386 is disposed between the reflector1382 and the reflective polarizer 1384. The reflector 1382 and retarderfilm 1386 may be the same as or similar to corresponding elements of theprojector 1110. The light source 1320 in combination with thebeamsplitter 1380 serves as an illuminator.

In this embodiment, the first prismatic body 1390 covers substantiallyall of the reflective polarizer 1384, and the first prismatic body 1390comprises two prisms—prism 390 and prism 396—in addition to the prism1392. The locations of the points a, b, c, d, e, f may be substantiallythe same as corresponding points in the projector 1110, hence, the prismdimensions H1, H2, HL1, and HL2, and their various ratios may satisfythe same conditions as discussed above.

FIG. 14 illustrates still another compact projector 1410 andilluminator. This projector combines the reflective cavity configurationdepicted in FIG. 1 with the use of a polarizing beamsplitter havingopposed prisms of substantially different sizes.

In this case, a light source 1420 injects an input light beam into areflective cavity 1430 formed by a reflector 1432 and a reflectivepolarizer 1434. A retarder film 1436 is disposed in the cavity, and anaperture 1438 is provided in the reflector 1432 and the retarder film1436. The reflector 1432, reflective polarizer 1434, and retarder film1436 may be applied to the outer surfaces of an optical lens or body1431 as shown, and may otherwise be the same as or similar tocorresponding components of the reflective cavity 430 in FIG. 4. Lightthat exits the reflective cavity 1430 enters a polarizing beamsplitter1480.

The polarizing beamsplitter 1480 includes an obliquely disposedreflective polarizer 1484 sandwiched between two opposed prismaticbodies: a first such prismatic body 1490 contains two facets 1492 a,1492 b which define a relatively small prism 1492, and the otherprismatic body is a relatively larger prism 1495. Polarized lightexiting the reflective cavity 1430 enters the beamsplitter 1480 througha facet of the prism 1495, and is reflected by the reflective polarizer1484 so that it exits the beamsplitter 1480 and impinges upon thespatial light modulator 1450. Light whose polarization is rotated by“on” pixels of the spatial light modulator 1450 re-enter thebeamsplitter 1480 and now pass through the reflective polarizer 1484,traverse the small prism 1492, and exit the beamsplitter 1480 by thefacet 1492 b. The boundaries of the small prism 1492 can be ascertainedby extending the facets 1492 a, 1492 b to the reflective polarizer 1484to define the labeled points c and b, respectively, and a third point,a, lies at the intersection of the facets 1492 a, 1492 b. The corners ofthe larger prism 1495 are clearly seen as labeled points d, e, and f.Attached to the lower side surface of the prism 1495 is a lens or otheroptical body having an exterior curved surface for optional focusing orconvergence of the exiting illumination beam. In this embodiment, thebeamsplitter 1480 need not contain any retarder film or reflector otherthan the reflective polarizer 1484.

The prisms 1492, 1495 have respective prism heights H1 and H2 as shown,and these parameters, as well as the respective hypotenuse lengths HL1and HL2, and their various ratios, may satisfy the same conditionsdiscussed above.

With reference to representative light ray 1444, a first ray portion1444 a has a first polarization state P1 which is substantiallyreflected by the reflective polarizer 1434, such that the reflected rayportion 1444 b passes through the retarder film 1436 and is reflected bythe reflector 1432. This reflection results in the ray portion 1444 cwhich passes again through the retarder film 1436, thereupon acquiringthe second polarization state P2 which is highly transmitted by thereflective polarizer 1434. The ray portion 1444 c thus passes throughthe reflective polarizer 1434 to provide ray portion 1444 d, whichenters the beamsplitter 1480 and is reflected by the reflectivepolarizer 1484 to produce reflected ray portion 1444 e. This ray exitsthe beamsplitter 1480 as ray portion 1444 f, reflects from an “on” pixelof the spatial light modulator 1450 (thus rotation the polarizationstate from P2 back to P1) as ray portion 1444 g, re-enters thebeamsplitter 1480 as ray portion 1444 h (still of polarization stateP1), now passes through the reflective polarizer 1484, traverses theprism 1492 as ray portion 1444i, and exits the beamsplitter 1480 atfacet 1492 b on its way to the projector lens 1460. Such light collectedby the projector lens 1460 ultimately forms the projected output beam1476 of the projector 1410. FIG. 14A is a magnified view of thereflector 1432 and retarder film 1436 on the outer surface 1431 a of theoptical body 1431.

FIG. 14B is a substantial duplicate of FIG. 14, where like referencenumbers designate like elements with no further need for discussion, andwhere two rectangular reference spaces 1403, 1405 are superimposed onthe figure. A first reference space 1403 is a rectangular space definedby the obliquely oriented reflective polarizer 1484. More specifically,the reference space 1403 is a rectangle whose diagonal line is thereflective polarizer 1484. A second reference space 1405 is the smallestrectangular space that encompasses the optical components of theprojector, i.e., the beamsplitter 1480, the light source 1420, thespatial light modulator 1450, and the projector lens 1460. Therelationships discussed above with respect to corresponding rectangularreference spaces, in connection with FIG. 11, can be seen to apply atleast in part to the reference spaces 1403, 1405 of the projector 1410also. In particular, the ratio of the area of reference space 1403 tothe area of reference space 1405 (A1/A2) is at least 45%.

The projector 1510 of FIG. 15 is similar to that of FIG. 14 insofar asit also combines the reflective cavity configuration depicted in FIG. 1with the use of a polarizing beamsplitter. However, the projector 1510also makes use of an unused side of the beamsplitter by adding adetector device, such that the projector 1510 is also capable offunctioning as a camera.

A light source 1520 injects an input light beam into a reflective cavity1530 formed by a reflector 1532 and a reflective polarizer 1534. Aretarder film 1536 is disposed in the cavity, and an aperture 1538 isprovided in the reflector 1532 and the retarder film 1536. The reflector1532, reflective polarizer 1534, and retarder film 1536 may be appliedto the outer surfaces of an optical lens or body 1531 as shown, and mayotherwise be the same as or similar to corresponding components of thereflective cavity 430 in FIG. 4. Light that exits the reflective cavity1530 enters a polarizing beamsplitter 1580.

The polarizing beamsplitter 1580 includes an obliquely disposedreflective polarizer 1584 sandwiched between two opposed prismaticbodies: a first prismatic body 1590 and a second prismatic body or prism1595. Polarized light exiting the reflective cavity 1530 enters thebeamsplitter 1580 through a facet of the prism 1595, and is reflected bythe reflective polarizer 1584 so that it exits the beamsplitter 1580 andimpinges upon the spatial light modulator 1550. Light whose polarizationis rotated by “on” pixels of the spatial light modulator 1550 re-enterthe beamsplitter 1480 and now pass through the reflective polarizer1584, traverse the prismatic body 1590, and exit the beamsplitter 1580in a well or hole sized to fit at least a part of the projector lens1560. Attached to the lower side surface of the prism 1595 is a lens orother optical body having an exterior curved surface for optionalfocusing or convergence of the exiting illumination beam. In thisembodiment, the beamsplitter 1580 need not contain any retarder film orreflector other than the reflective polarizer 1584. With reference torepresentative light ray 1544, a first ray portion 1544 a has a firstpolarization state P1 which is substantially reflected by the reflectivepolarizer 1534, such that the reflected ray portion 1544 b passesthrough the retarder film 1536 and is reflected by the reflector 1532.This reflection results in the ray portion 1544 c which passes againthrough the retarder film 1536, thereupon acquiring the secondpolarization state P2 which is highly transmitted by the reflectivepolarizer 1534. The ray portion 1544 c thus passes through thereflective polarizer 1534 to provide ray portion 1544 d, which entersthe beamsplitter 1580 and is reflected by the reflective polarizer 1584to produce reflected ray portion 1544 e. This ray exits the beamsplitter1580 as ray portion 1544 f, reflects from an “on” pixel of the spatiallight modulator 1550 (thus rotation the polarization state from P2 backto P1) as ray portion 1544 g, re-enters the beamsplitter 1580 as rayportion 1544 h (still of polarization state P1), now passes through thereflective polarizer 1584, traverses the prismatic body 1590 as rayportion 1544i, and exits the beamsplitter 1580 on its way to theprojector lens 1560. Such light collected by the projector lens 1560ultimately forms a projected output beam of the projector 1510.

Incoming light ray 1545 represents light originating from a body outsideof the projector, but passing through the projector lens 1545. A firstray portion 1545 a enters the projector lens 1560, exits the lens 1560as ray portion 1545 b, and enters the beamsplitter 1580 as ray portion1545 c. Assuming the ray portion 1545 a was originally unpolarized, theray portion 1545 c will also be unpolarized, and will contain bothcomponents of the first polarization state P1 and of the secondpolarization state P2 as shown.

When the ray portion 1545 c encounters the reflective polarizer 1584,the P1 polarization state will be transmitted into a ray portion 1545 d,and the P2 polarization state will be reflected into a ray portion 1545e, which then exits the beamsplitter 1580 at an unused facet thereof,where a detector device 1596 has been placed. The detector device 1596is shown as having an array of detector elements, such as in acharge-coupled device (CCD) detector array, but other known detectorarrays or even an individual detector element may also be used. Byincluding the detector device 1596 in the projector 1510, the sameprojector lens 1560 that is used to project an image to a remotelocation can also be used to collect light from the remote location andcapture that light as a camera image or the like. Such a detector devicecan also be incorporated into the projector 1410 of FIG. 14 by placingthe same or similar array at the unused facet 1492 a, or at a spaceddistance from such facet 1492 a with one or more lenses or other opticalelements disposed therebetween.

FIG. 15A is a substantial duplicate of FIG. 15, where like referencenumbers designate like elements with no further need for discussion, andwhere two rectangular reference spaces 1503, 1505 are superimposed onthe figure. A first reference space 1503 is a rectangular space definedby the obliquely oriented reflective polarizer 1584. More specifically,the reference space 1503 is a rectangle whose diagonal line is thereflective polarizer 1584. A second reference space 1505 is the smallestrectangular space that encompasses the optical components of theprojector, namely, the beamsplitter 1580, the light source 1520, thespatial light modulator 1550, the projector lens 1560, and the detectordevice 1596. The relationships discussed above with respect tocorresponding rectangular reference spaces, in connection with FIG. 11,can be seen to apply at least in part to the reference spaces 1503, 1505of the projector 1510 also. In particular, the ratio of the area ofreference space 1503 to the area of reference space 1505 (A1/A2) is atleast 40%.

FIG. 16 schematically illustrates still another projector andillumination system. The projector 1610 requires no reflective cavity orbeamsplitter. Rather, light from a light source 1620, as represented byray portion 1644 a of a representative light ray 1644, is simplycollected by a pair of lenses L1, L2, although more or fewer than twolenses can be used. The lenses focus the light to produce a convergingoutput illumination beam, represented by ray portion 1644 b. This beamimpinges upon a transmissive spatial light modulator 1650, producing aspatially patterned beam as represented by ray portion 1644 c. Thespatially patterned beam is then collected and projected to a remotelocation by a projector lens 1660. As a result of the convergingillumination beam, the projector lens 1660, or at least one of itsindividual component lenses, may have a maximum lateral dimension LD1(e.g. as measured along the x-axis, or along the y-axis, or along adiagonal of the spatial light modulator 1650) that is less than thecorresponding lateral dimension LD2 of the spatial light modulator 1650,or that alternatively satisfies the relationship 30%<LD1/LD2<70%

Unless otherwise indicated, all numbers expressing quantities,measurement of properties, and so forth used in the specification andclaims are to be understood as being modified by the term “about”.

Accordingly, unless indicated to the contrary, the numerical parametersset forth in the specification and claims are approximations that canvary depending on the desired properties sought to be obtained by thoseskilled in the art utilizing the teachings of the present application.Not as an attempt to limit the application of the doctrine ofequivalents to the scope of the claims, each numerical parameter shouldat least be construed in light of the number of reported significantdigits and by applying ordinary rounding techniques. Notwithstandingthat the numerical ranges and parameters setting forth the broad scopeof the invention are approximations, to the extent any numerical valuesare set forth in specific examples described herein, they are reportedas precisely as reasonably possible. Any numerical value, however, maywell contain errors associated with testing or measurement limitations.The following are embodiments of the present invention.

Embodiment 1 is a compact projector, comprising: a beamsplittercomprising a reflective polarizer, the reflective polarizer obliquelydisposed to define a diagonal of a first rectangular reference space; alight source disposed proximate the reflective polarizer, the lightsource configured to emit an input light beam towards the reflectivepolarizer; a spatial light modulator disposed to receive an outputillumination beam derived from the input light beam, the spatial lightmodulator adapted to selectively reflect the output illumination beam toprovide a patterned light beam; and a projector lens adapted to receivethe patterned light beam; wherein the beamsplitter, the light source,the spatial light modulator, and the projector lens are encompassed by asecond rectangular reference space; and wherein the first rectangularreference space has an area A1 and the second rectangular referencespace has an area A2, and wherein 30%<A1/A2<70%.

Embodiment 2 is the projector of embodiment 1, wherein 40%<A1/A2<70%.

Embodiment 3 is the projector of embodiment 1, wherein the beamsplittercomprises a first prism and a second prism disposed on opposite sides ofthe reflective polarizer.

Embodiment 4 is the projector of embodiment 3, wherein the first andsecond prisms have respective first and second hypotenuse lengths HL1and HL2, and wherein 40%<HL1/HL2<70%.

Embodiment 5 is the projector of embodiment 3, wherein the first andsecond prisms have respective first and second prism heights H1 and H2,and wherein 40%<H1/H2<70%.

Embodiment 6 is the projector of embodiment 1, wherein the projectorlens has a maximum lateral dimension LD1 and the spatial light modulatorhas a maximum lateral dimension LD2, and wherein LD1 is less than LD2.

Embodiment 7 is the projector of embodiment 6, wherein 30%<LD1/LD2<70%.

Embodiment 8 is the projector of embodiment 1, wherein the light sourcecomprises an LED die and a polarizer, and wherein the input light beamis polarized.

Embodiment 9 is the projector of embodiment 1, wherein the projectorfurther comprises a detector to receive light originating from a bodyoutside of the projector through the projector lens.

Embodiment 10 is a compact projector, comprising: a reflective polarizerobliquely disposed to define a diagonal of a first rectangular referencespace; a light source disposed proximate the reflective polarizer, thelight source configured to emit an input light beam towards thereflective polarizer; a spatial light modulator disposed to receive anoutput illumination beam derived from the input light beam, the spatiallight modulator adapted to selectively reflect the output illuminationbeam to provide a patterned light beam; a projector lens adapted toreceive the patterned light beam; wherein at least a portion of thelight source, or at least a portion of the projector lens, is disposedwithin the first rectangular reference space.

Embodiment 11 is the projector of embodiment 10, wherein the at least aportion of the light source and the at least a portion of the projectorlens are both disposed within the first rectangular reference space.

Embodiment 12 is the projector of embodiment 10, wherein only one of theat least a portion of the light source and the at least a portion of theprojector lens is disposed within the first rectangular reference space.

Embodiment 13 is the projector of embodiment 11, wherein the reflectivepolarizer divides the first rectangular reference space into a firstportion and a second portion, and wherein the at least a portion of thelight source, or the at least a portion of the projector lens, isdisposed within the first portion of the first rectangular referencespace.

Embodiment 14 is the projector of embodiment 13, wherein the at least aportion of the light source and the at least a portion of the projectorlens are both disposed within the first portion of the first rectangularreference space.

Embodiment 15 is the projector of embodiment 10, wherein the lightsource comprises an LED die, and wherein the LED die is entirelydisposed within the first rectangular reference space.

Embodiment 16 is the projector of embodiment 10, wherein the projectorlens comprises a plurality of individual lenses in series, and whereinat least one of the individual lenses is entirely disposed within thefirst rectangular reference space.

Embodiment 17 is the projector of embodiment 10, wherein the reflectivepolarizer is part of a beamsplitter that also includes a first andsecond prism disposed on opposite sides of the reflective polarizer.

Embodiment 18 is the projector of embodiment 17, wherein the first andsecond prisms have respective first and second hypotenuse lengths HL1and HL2, and wherein 40%<HL1/HL2<70%.

Embodiment 19 is the projector of embodiment 17, wherein the first andsecond prisms have respective first and second prism heights H1 and H2,and wherein 40%<H1/H2<70%.

Embodiment 20 is the projector of embodiment 10, wherein the projectorlens has a maximum lateral dimension LD1 and the spatial light modulatorhas a maximum lateral dimension LD2, and wherein LD1 is less than LD2.

Embodiment 21 is the projector of embodiment 20, wherein30%<LD1/LD2<70%.

Embodiment 22 is the projector of embodiment 10, wherein the projectorfurther comprises a detector to receive light originating from a bodyoutside of the projector through the projector lens.

Embodiment 23 is a polarizing beamsplitter, comprising: a firstprismatic body comprising a first prism; a second prismatic bodycomprising a second prism; and a reflective polarizer sandwiched betweenthe first and second prismatic bodies; wherein the first prism issubstantially smaller than the second prism.

Embodiment 24 is the beamsplitter of embodiment 23, wherein the firstand second prisms have respective first and second hypotenuse lengthsHL1 and HL2, and wherein 40%<HL1/HL2<70%.

Embodiment 25 is the beamsplitter of embodiment 23, wherein the firstand second prisms have respective first and second prism heights H1 andH2, and wherein 40%<H1/H2<70%.

Embodiment 26 is the beamsplitter of embodiment 23, wherein thebeamsplitter is configured such that light that passes through the firstprismatic body passes predominantly through the first prism.

Embodiment 27 is the beamsplitter of embodiment 26, wherein thereflective polarizer comprises a first major surface facing the firstprismatic body, and wherein the first prismatic body covers most of thefirst major surface.

Embodiment 28 is the beamsplitter of embodiment 27, wherein the firstprismatic body covers substantially all of the first major surface.

Embodiment 29 is the beamsplitter of embodiment 23, wherein the firstprismatic body comprises at least one prism other than the first prism.

Embodiment 30 is the beamsplitter of embodiment 23, wherein the firstprismatic body comprises no prisms other than the first prism.

Embodiment 31 is a compact polarized illuminator, comprising: areflector; a reflective polarizer disposed to form a reflective cavitywith the reflector; a retarder film disposed within the reflectivecavity; and a light source disposed to emit a polarized input light beaminto the reflective cavity through an aperture in the reflector; whereinthe reflector, the reflective polarizer, and the retarder film areconfigured to produce an output illumination beam from the input lightbeam, and wherein the output illumination beam is polarized.

Embodiment 32 is the illuminator of embodiment 31, wherein at least oneof the reflector and the reflective polarizer is curved, and wherein theoutput illumination beam is converging.

Embodiment 33 is the illuminator of embodiment 31, wherein light followsa light path from the light source to the output illumination beam thatincludes passing through the aperture, reflecting from the reflectivepolarizer, reflecting from the reflector, passing through the reflectivepolarizer, and passing at least two times through the retarder film.

Embodiment 34 is the illuminator of embodiment 31, wherein thereflective cavity defines a cavity volume, and a majority of the cavityvolume comprises at least one solid light-transmissive material.

Embodiment 35 is the illuminator of embodiment 31, wherein thereflective cavity defines a cavity volume, and a majority of the cavityvolume comprises air or vacuum.

Embodiment 36 is the illuminator of embodiment 31, wherein the retarderfilm is proximate the reflector, and the aperture is also in theretarder film.

Embodiment 37 is the illuminator of embodiment 31, wherein theilluminator further comprises a scattering element to make the outputillumination beam more spatially uniform.

Embodiment 38 is the illuminator of embodiment 37, wherein thescattering element comprises a roughened surface, and the roughenedsurface is part of the reflective cavity.

Embodiment 39 is the illuminator of embodiment 37, wherein thescattering element comprises a layer of scattering material within thereflective cavity.

Embodiment 40 is the illuminator of embodiment 31, wherein the lightsource comprises an LED and a polarizer.

Embodiment 41 is a compact polarized illuminator, comprising: areflector; a reflective polarizer disposed obliquely relative to thereflector; a retarder film disposed between the reflector and thereflective polarizer; and a light source disposed to emit an input lightbeam of a first polarization state through the reflective polarizertowards the reflector; wherein the reflector, the reflective polarizer,and the retarder film are configured to produce an output illuminationbeam from the input light beam, and wherein the output illumination beamhas a second polarization state orthogonal to the first polarizationstate.

Embodiment 42 is the illuminator of embodiment 41, wherein thereflective polarizer is part of a beamsplitter that also includes afirst and second prism disposed on opposite sides of the reflectivepolarizer.

Embodiment 43 is the illuminator of embodiment 42, wherein the first andsecond prisms have respective first and second hypotenuse lengths HL1and HL2, and wherein 40%<HL1/HL2<70%.

Embodiment 44 is the illuminator of embodiment 42, wherein the first andsecond prisms have respective first and second prism heights H1 and H2,and wherein 40%<H1/H2<70%.

Embodiment 45 is a projector, comprising: the polarized illuminator ofembodiment 31; a spatial light modulator disposed to intercept theoutput illumination beam so as to produce a spatially patterned beam;and a projector lens to receive the spatially patterned beam.

Embodiment 46 is the projector of embodiment 45, wherein the spatiallight modulator is a transmissive spatial light modulator.

Embodiment 47 is the projector of embodiment 45, wherein the spatiallight modulator is a reflective spatial light modulator.

Embodiment 48 is the projector of embodiment 45, wherein the projectorlens has a maximum lateral dimension LD1 and the spatial light modulatorhas a maximum lateral dimension LD2, and wherein LD1 is less than LD2.

Embodiment 49 is the projector of embodiment 45, wherein the projectorfurther comprises a detector to receive light originating from a bodyoutside of the projector through the projector lens.

Embodiment 50 is a projector, comprising: the polarized illuminator ofembodiment 41; a spatial light modulator disposed to intercept theoutput illumination beam so as to produce a spatially patterned beam;and a projector lens to receive the spatially patterned beam.

Embodiment 51 is the projector of embodiment 50, wherein the spatiallight modulator is a reflective spatial light modulator.

Embodiment 52 is the projector of embodiment 50, wherein the projectorlens has a maximum lateral dimension LD1 and the spatial light modulatorhas a maximum lateral dimension LD2, and wherein LD1 is less than LD2.

Embodiment 53 is the projector of embodiment 50, wherein the projectorfurther comprises a detector to receive light originating from a bodyoutside of the projector through the projector lens.

Various modifications and alterations of this invention will be apparentto those skilled in the art without departing from the spirit and scopeof this invention, and it should be understood that this invention isnot limited to the illustrative embodiments set forth herein. The readershould assume that features of one disclosed embodiment can also beapplied to all other disclosed embodiments unless otherwise indicated.It should also be understood that all U.S. patents, patent applicationpublications, and other patent and non-patent documents referred toherein are incorporated by reference, to the extent they do notcontradict the foregoing disclosure.

1. A compact polarized illuminator, comprising: a reflector; areflective polarizer disposed to form a reflective cavity with thereflector; a retarder film disposed within the reflective cavity; and alight source disposed to emit a polarized input light beam into thereflective cavity through an aperture in the reflector; wherein thereflector, the reflective polarizer, and the retarder film areconfigured to produce an output illumination beam from the input lightbeam, and wherein the output illumination beam is polarized.
 2. Thecompact polarized illuminator of claim 1, wherein at least one of thereflector and the reflective polarizer is curved, and wherein the outputillumination beam is converging.
 3. The compact polarized illuminator ofclaim 1, wherein light follows a light path from the light source to theoutput illumination beam that includes passing through the aperture,reflecting from the reflective polarizer, reflecting from the reflector,passing through the reflective polarizer, and passing at least two timesthrough the retarder film.
 4. The compact polarized illuminator of claim1, wherein the reflective cavity defines a cavity volume, and a majorityof the cavity volume comprises at least one solid light-transmissivematerial.
 5. The compact polarized illuminator of claim 1, wherein thereflective cavity defines a cavity volume, and a majority of the cavityvolume comprises air or vacuum.
 6. The compact polarized illuminator ofclaim 1, wherein the retarder film is proximate the reflector, and theaperture is also in the retarder film.
 7. The compact polarizedilluminator of claim 1, wherein the illuminator further comprises ascattering element to make the output illumination beam more spatiallyuniform.
 8. The compact polarized illuminator of claim 7, wherein thescattering element comprises a roughened surface, and the roughenedsurface is part of the reflective cavity.
 9. The compact polarizedilluminator of claim 7, wherein the scattering element comprises a layerof scattering material within the reflective cavity.
 10. The compactpolarized illuminator of claim 1, wherein the light source comprises anLED and a polarizer.
 11. A projector, comprising: the compact polarizedilluminator of claim 1; a spatial light modulator disposed to interceptthe output illumination beam so as to produce a spatially patternedbeam; and a projector lens to receive the spatially patterned beam. 12.The projector of claim 11, wherein the spatial light modulator is atransmissive spatial light modulator.
 13. The projector of claim 11,wherein the spatial light modulator is a reflective spatial lightmodulator.
 14. The projector of claim 11, wherein the projector lens hasa maximum lateral dimension LD1 and the spatial light modulator has amaximum lateral dimension LD2, and wherein LD1 is less than LD2.
 15. Theprojector of claim 11, wherein the projector further comprises adetector to receive light originating from a body outside of theprojector through the projector lens.